Shapeable vacuum insulation panel containing a single core component

ABSTRACT

A shapeable vacuum insulation panel containing a single core component is particularly useful for preparing thermally insulating containers.

CROSS REFERENCE STATEMENT

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/282,250, filed Apr. 6, 2001.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to shapeable vacuum insulationpanels, each containing a single core component, and insulatingcontainers containing at least one such shapeable panel.

[0004] 2. Description of Related Art

[0005] Vacuum insulation panels (VIPs) comprise a gas-impermeablebarrier enclosing an evacuated airtight volume. Typically, the airtightvolume contains at least one core component within the airtight volume.Evacuating the airtight volume reduces the thermal conductivity throughthe volume, making VIPs particularly effective thermal insulatingmaterials.

[0006] Constructing insulating containers using VIPs is challenging andtime consuming. VIPs are often planar while containers are not.Insulating rectilinear containers having two or more surfaces typicallyrequires piecing together two or more VIPs, one for each surface.Insulating cylindrical containers with VIPs requires either customizedVIPs or at least one flexible vacuum insulation panel that can conformto the cylindrical configuration. Custom VIPs are complex to manufactureand limited in their use to the custom application. Flexible VIPs areversatile, but flexible VIP technology is limited. United States patentsU.S. Pat. Nos. 4,726,974; 5,107,649; 5,175,975; 5,273,801; and 6,010,762as well as Patent Cooperation Treaty (PCT) publication WO 96/32605disclose examples of flexible VIPs.

[0007] U.S. Pat. No. 4,726,974 discloses a VIP comprising a shaped andcompressed fiberglass substrate in an enclosure that is under vacuum.The fiberglass substrate is an article having a specific shape forconforming to a specific container, for example a curved article forinsulating a cylindrical container. Fiberglass, however, is challengingto implement in a VIP. Binders are necessary to inhibit individualfiberglass fibers from piercing the enclosure or protruding into orthrough the enclosure while manufacturing the VIP.

[0008] U.S. Pat. No. 5,107,649 and U.S. Pat. No. 5,175,975 both disclosea VIP comprising two hard but bendable metal sheets welded togetheraround the edges and spaced apart with glass or ceramic spacers. Thebendable VIPs contain multiple discrete spacers.

[0009] U.S. Pat. No. 5,273,801 discloses a VIP comprising a thermoformedvacuum insulation container having a receptacle area for microporousinsulation material. The container may have multiple receptacle areasand may fold at least 90° along a line between adjacent receptacleareas. Each receptacle area receives microporous insulation material inloose form or in a pre-filled package.

[0010] U.S. Pat. No. 6,010,762 discloses an insulation panel comprisingan air-impermeable container having disposed therein a gas and anadsorbent material. The combination of a flexible container and aflexible adsorbent material ensures that the insulation panel will beflexible at ambient temperature. The panel loses flexibility, however,upon evacuation.

[0011] PCT 96/32605 discloses a non-planar evacuated insulation panelcontaining an insulating filler material and a method for preparing suchan insulation panel by providing grooves in the filler material prior toforming the evacuated insulation panel. The panel can bend along thegroove in the filler material.

[0012] The flexible VIPs of the cited USPs and PCT publication are lessthan optimal, suffering from one or more of the following handicaps:fiberglass in the cores that can breach a gas-impermeable barrier,multiple discrete core components requiring specific placement withinthe VIP, limited flexibility, and a requirement that the VIP contain aninsulating material containing a groove. A flexible VIP that can conformto a variety of container shapes after formation is desirable,particularly if its core is not made of fiberglass. Such a shapeable VIPcontaining a single core component rather than discrete core componentsis even more desirable. Such a VIP that does not require an insulatingmaterial containing a groove further advances the art of VIPs.

BRIEF SUMMARY OF THE INVENTION

[0013] In a first aspect, the present invention is a vacuum insulationpanel comprising a single core component enclosed within agas-impermeable barrier; wherein said vacuum insulation panel can bendor fold at least 90 degrees (°) relative to an initial configurationwithout breaking said single core component into two or more discretepieces when said single core component is free of grooves; and whereinsaid single core component contains less than 50 weight-percent (wt %)of fiberglass fibers, based on single core component weight. In onepreferred variation of the first aspect, the single core componentcontains at least one core component section comprising a polymeric foamthat is 90 percent or more open-celled according to American Society forTesting and Materials (ASTM) method D2856-A.

[0014] In a second aspect, the present invention is an insulatedcontainer comprising at last one vacuum insulation panel of the firstaspect.

[0015] In a third aspect, the present invention is a method ofinsulating a container shell comprising: (a) bending the vacuuminsulation panel of the first aspect into a desired configuration; then(b) disposing the vacuum insulation panel into or around said containershell.

[0016] The present invention advances the art with a vacuum insulationpanel that is shapeable after formation and that contains a single corecomponent.

BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure (FIG) 1 a shows a cut-away view of a VIP of the presentinvention containing a single core component comprising two indirectlyinterconnected core component sections in a first configuration.

[0018] FIG 1 b shows another cut-away view of the VIP of FIG 1 a afterbending 90° into a second configuration.

[0019]FIG. 2a shows an indirectly interconnected single core componentcomprising six core component sections.

[0020]FIG. 2b shows the single core component of FIG. 2a after bendinginto a container configuration.

[0021]FIG. 3a shows a core component section with beveled edges.

[0022]FIG. 3b shows a core component containing five interconnectingcore component sections similar to that in FIG. 3a.

[0023] FIG 3 c shows the core component of FIG. 3b bent into a wallconfiguration.

[0024]FIG. 4 shows an insulated container with a shapeable VIP of thepresent invention within a container shell.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Herein, “shapeable” describes an object that is capable ofbending 90° or more without breaking. Herein, “bending” and “folding”are interchangeable. An object bends a certain number of degrees bydisplacing one of two opposing ends of the object that certain number ofdegrees relative to the other end without breaking the object.

[0026] Shapeable VIPs of the present invention contain a single corecomponent hermetically sealed within a gas-impermeable barrier. Thesingle core component resides in a vacuum within the gas impermeablebarrier material. The shapeable VIP is capable of bending 90° or more,preferably 180° or more without breaking the single core component intotwo or more discrete pieces. For example, FIG 1 a shows VIP 5 in aninitial configuration and FIG 1 b shows VIP 5 bent 90° relative to theinitial configuration in FIG 1 a.

[0027] VIPs of the present invention are shapeable even when the corecomponent of the VIP is free of grooves. Grooves extend from one end toanother end in a chosen direction. WO 96/32605 (incorporated herein byreference) describes VIPs with core components. A method for preparinggrooves in a core component and a definition of a “groove” is on page10, lines 7-17 of WO 96/32605. While grooves are not necessary, corecomponents of the present invention can contain grooves or be free ofgrooves.

[0028] The vacuum within the gas-impermeable barrier is preferably 10torr (1,330 pascal (Pa)) or less, more preferably 1 torr (133 Pa) orless, most preferably 0.1 torr (13.3 Pa) or less. Lower pressures arepreferable to achieve lower thermal conductivity through the VIP. A VIPthat has a pressure greater than 10 torr (1,330 Pa) tends to have anundesirably high thermal conductivity.

[0029] A gas-impermeable barrier in the present invention preferably hasa gas permeation rate of 1.5 cubic centimeter per day per square meter(cc/day/m²) or less, more preferably 0.15 cc/day/m² or less, mostpreferably 0.015 cc/day/m² or less. Measure gas permeation rateaccording to ASTM method D-3985. A VIP having a gas-impermeable barrierhaving a gas permeation rate of greater than 1.5 cc/day/m² tends to losevacuum and insulating properties more quickly than is desirable.

[0030] Suitable materials for use as gas-impermeable barriers includemetal sheet, metal foil, polymeric film, and combinations thereof. Somematerials, such as metal sheet, tend to be rigid and preferably containcorrugation to enhance flexibility, allowing a VIP to be shapeable.Corrugation may be uniform along the rigid material or only occur insections of the material where bending or folding occurs. U.S. Pat. No.5,175,975 (column 9 lines 3-16 and line 29-36 and FIGS. 16, 17, and 19,incorporated herein by reference) describes examples of corrugated metalsheets as VIP gas barrier materials. U.S. Pat. No. 5,175,975 describesplanar VIPs in which corrugations are in a direction parallel to anX-axis when the VIP is in a plane containing X and Y axes. Thecorrugations allow the VIP to move in the +Z and −Z axis while remainingrigid in the X-axis.

[0031] Preferably, the gas-impermeable barrier is a polymeric film.Polymeric films offer a desirable combination of flexibility anddurability. Suitable polymeric films can contain any common polymer orcombination of polymers provided the films have a gas permeation rate of1.5 cc/day/m² or less, according to ASTM method D-3985. Polymeric filmsmay contain, for example, polyesters, copolyesters, tetrafluoroethylene,polyimide, polyvinylidene chloride, polyvinyl chloride, polyvinylalcohol (PVOH), polystyrene (PS) polymers and copolymers, polyethylene(PE) polymers and copolymers, and polypropylene (PP) polymers andcopolymers.

[0032] Polymeric films may include a coating disposed on at least onesurface to reduce gas permeability of the film. Suitable coatingsinclude those selected from the group consisting of inorganic materials,such as a metal, ceramic, or glass, as well as organic materials such aspolyvinylidene chloride (PVDC). Suitable metals include gold, aluminumand silver. Suitable means for coating a film include any method knownin the art such as plasma coating, sputter coating, spray coating, andelectromagnetic bonding.

[0033] More preferably, the gas-impermeable barrier is a multilayerfilm, desirably having an exposed layer that is heat sealable. Oneparticularly preferred multilayer film comprises an outer layer, amiddle layer and an inner layer. The outer layer desirably comprises ascratch resistant material such as a polyester or copolyester. Themiddle layer desirably consists of a barrier material such as aluminum,PVDC, PVOH, or a polymeric film having a coating of aluminum. The innerlayer desirably contains a heat sealable material such as PE,ethylene/acrylic acid copolymer, PE-vinylacetate copolymer, high densityPE, and PP blends. Lamination, extrusion coating, and coextrusion areall suitable means for preparing gas-impermeable multilayer films.Commercially available multilayer films suitable as barrier materialsfor the present invention are also available and include films NA-1,NA-2, NA-3, and NA-4 from Toyo Aluminum K.K.; aluminum foil containingfilms SA-1, SA-2, SA-3, SA-4, SA-5, and SA-6, also from Toyo AluminumK.K.; and MYLAR™ (trademark of E. I. du Pont de Nemours and Company) 200RSBL, MYLAR 250 RSBL 300, and MYLAR 350 RSBL 300 polyester films.

[0034] A skilled artisan can determine any of a number of ways tohermetically seal a suitable barrier material. For example, one can weldmetal sheets together and heat-seal or melt polymeric films together. Ifnecessary, one may use an additional adhesive or glue to hermeticallyseal together sheets or plies of the barrier material.

[0035] The shapeable VIP contains a singe core component that may or maynot be shapeable apart from the VIP. For example, some PS foams may notbe shapeable until they are under vacuum within a VIP and supported by agas-impermeable barrier.

[0036] Herein, “single core component” refers to a core componentcomprising a single structure. A single core component enables fast andsimple manufacture of a VIP. For example, manufacturing a VIP with asingle core component can involve inserting the core component into agas-impermeable barrier receptacle (such as a bag); evacuating thereceptacle; and hermetically sealing the receptacle. In contrast,manufacturing VIPs that contain two or more discrete core componentsrequires specific placement of each core component. Discrete corecomponents may disadvantageously move or re-orient relative to oneanother during manufacture. A VIP of the present invention requiresplacement of only a single core component and minimizes the risk ofdiscrete core components moving during manufacture.

[0037] A single core component may comprise a single core componentsection or two or more interconnected core component sections. A “corecomponent section” is a portion of a single core component that extendsfrom one face to an opposing face of the single core component.

[0038] A shapeable VIP of the present invention that has a corecomponent consisting of a single core component section ischaracterizable by a “D/T” ratio. “T” is the thickness of the VIP and“D” is the smallest diameter of a mandrel about which the VIP will bend90° without breaking the core component into discrete pieces. Measure“T” and “D” using the same units. Dividing T into D achieves the D/Tratio, a unitless value. The D/T ratio for a shapeable VIP having a corecomponent comprising a single core component section is greater thanzero, generally one or more. The D/T ratio is preferably 48 or less,more preferably 24 or less, still more preferably 12 or less, mostpreferably 8 or less. VIPs having a D/T ratio of greater than 48 lacksufficient flexibility for most uses requiring a flexible VIP.

[0039] Alternatively, a single core component may contain two or moreinterconnected core component sections. Interconnecting core componentsections may be the same or different. For example, interconnecting corecomponent sections may have different compositions, densities,structures, and sizes. Core component sections may be directlyinterconnected, indirectly interconnected, or a combination of both.

[0040] Directly interconnected core component sections attach directlyto each other without the use of a connector. For example, melt-weldingpolymeric foam boards together directly interconnects the boards. VIPsthat have a single core component consisting of only directlyinterconnected core component sections are preferably characterizable bya D/T ratio and the D/T ratio values previously specified.

[0041] Indirectly interconnected core component sections utilize atleast one connector to join the core component sections together. Twoindirectly interconnected core component sections may or may not betouching each other and include a connector with one portion of theconnector attached to one core component section and another portion ofthe connector attached to the other core component section.

[0042] Connectors may be flexible or rigid. Flexible connectors arepreferable because they tend to contribute to a VIP's flexibility. Aconnector that can bend at least 90° without fracturing is a “flexible”connector. A connector that fractures upon bending 90° is a “rigid”connector. Flexible connectors may become rigid connectors under certainconditions, and vice versa. For example, a polymeric film may be aflexible connector at or near its glass transition temperature (Tg) yetbe rigid connector 100° C. below its Tg. Therefore, whether a connectoris a rigid connector or a flexible connector is dependent upon what theconnector is made of and at what temperature it is at. Herein,connectors are considered to be at 23° C. unless otherwise indicated.

[0043] Suitable connectors include those selected from the groupconsisting of polymeric films and foams, adhesive films, corrugatedmetal, adhesive tape, paper, metal foil, string, and wire. Flexibleglues and adhesives, such as silicone rubber are also suitable flexibleconnectors. Polymeric films and adhesive tapes, such as SCOTCH™ brandadhesive tape (SCOTCH is a trademark of 3M) are desirable connectors.Polymeric films comprising at least one polymer selected from the groupconsisting of polyesters, PE, PS, and copolymers thereof are moredesirable. Polymeric films may comprise more than one layer to achievedesired properties. For example, a polymeric film having opposingsurfaces may include an adhesive layer on one surface and a durable filmlayer on an opposing surface.

[0044] A shapeable VIP containing only core component sections directlyinterconnected by rigid connectors typically bend within at least onecore component section. As such, the VIP preferably has a D/T ratio inthe previously specified ranges. Alternatively, the VIP is onlyshapeable under conditions that transform any rigid connector (orconnectors) between any two core component sections into a flexibleconnector (or connectors), thereby allowing the VIP to bend along theconnector(s).

[0045] Core component sections beneficially comprise highly open-celledfoam. “Highly open-celled” foams are 90% or more open-celled, preferably95% or more open-celled, more preferably 98% or more open-celled, mostpreferably 99% or more open-celled according to ASTM method D2856-A.Foams that are less than 90% open-celled are difficult to evacuate whenmanufacturing a VIP. Highly open-celled foams may be inorganic, such asceramic or glass, or organic, such as cellulose or organicpolymer-based. More preferably, core component sections are highlyopen-celled polymeric foam comprising at least one polymer. Preferredpolymers include those selected from the group consisting of alkenylaromatic homo- and copolymers including PS homo- and copolymers, PPhomo- and copolymers, PE homo- and copolymers, polycarbonate homo- andcopolymers, polyurethane (PU) polymers, polyisocyanurate polymers, andblends thereof. Examples of suitable polymer blends include blends of analkenyl aromatic polymer and an ethylene copolymer such as anethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer,ethylene-methacrylic acid copolymer, ethylene-methyl acrylate copolymer,ethylene-ethylacrylate copolymer, ionomer, or an ethylene copolymer madewith either constrained geometry or metallocene catalyst technology.Most preferably, a core component section comprises a highly open-celledPS foam.

[0046] A core component section may comprise particulate or fibrousmaterials, provided the materials interconnect or are within acontainer. For instance, NANOGEL™ advanced thermal insulation (NANOGELis a trademark of Cabot Corporation) is an example of particulatematerial inside of a bag that is suitable as a core component sectionwithin the scope of this invention. Suitable particulate materialsinclude open-celled porous materials such as silica gel, titania gel,alumina gel; and polymeric gels such as resocinol-formaldehyde gels, andmelamine formaldehyde gels. Fibrous materials include fiberglass,glasswool, and mineral wool. However, a single core component of thepresent invention contains less than 50 wt %, preferably less than 25 wt%, more preferably less than 10 wt % of fiberglass fibers relative tocore component weight.

[0047] Core component sections are preferably essentially free offibrous material such as fiberglass, glass wool, and mineral wool. Acore component section is essentially free of fibrous material when itcontains 10 wt % or less, preferably 5 wt % or less, more preferably 1wt % or less of fibrous material by weight of the core componentsection. A core component that is essentially free of fibrous materials,particularly fiberglass, minimizes the chance that fibers may puncturethe barrier material or breach the hermetic seal by traversing the sealduring manufacture.

[0048] Particulate or fibrous materials may interconnect mechanically,adhesively, or chemically. For example, interweaving fibers mechanicallybinds them together. Glue or non-reactive binders can adhesively bindparticles or fibers together. Reactive binders, such as those thatchemically crosslink fibrous or particulate materials together, canchemically bind fibers and particles. Interconnected non-porousparticles and fibers preferably have void spaces between particles orfibers to reduce the VIP density and facilitate evacuation of the VIP.

[0049] There are many suitable configurations for interconnecting corecomponent sections with at least one connector, some of which areevident in FIGS 1 a, 1 b, 2 a, 2 b, 3 b, and 3 c. Like numbers indifferent figures refer to the same feature.

[0050] FIG 1 a shows a cut-away view of VIP 5 in an initialconfiguration. VIP 5 contains core component 10 within gas-impermeablebarrier 8. Core component 10 contains two indirectly interconnected corecomponent sections 12 and 14. Core component section 12 has edge 17(shown only in FIG 1 a) that is proximate to core component section 14.Flexible connector 16 adheres to a surface portion of both corecomponent sections 12 and 14, thereby interconnecting them. Corecomponent section 14 has a thickness T (shown only in FIG 1 a), whilecore component section 12 has thickness T′ (shown only in FIG 1 a).Thickness T and thickness T′ may be the same or different. Corecomponent sections 12 and 14 are spaced a distance S (shown only in FIG1 a) apart. The magnitude of distance S is preferably the same as thatof thickness T.

[0051] FIG 1 b shows VIP 5 in a configuration bent 90° by way offlexible connector 16, relative to the initial configuration shown inFIG 1 a. When thickness T and spacing S are the same, edge 17 of corecomponent 12 contacts face 18 (not shown) of core component 14, forminga fully insulated right angle corner, as shown in FIG 1 b. Variations inthickness T and spacing S can allow VIP 5 to bend to angles other than9020 . For instance, increasing spacing S while maintaining thickness T,or decreasing thickness T while maintaining spacing S can allow VIP 5 tobend more than 90°.

[0052] A single connector may simultaneously connect two or more corecomponent sections, as FIGS. 2a and 2 b show. FIG. 2a shows single corecomponent 20 containing core component connectors 30 and 32simultaneously interconnecting core component sections 22, 24, 26, and28. Connectors 30 and 32 can be, for example, adhesive tape extendingacross and attaching to surface portions of core component sections 22,24, 26, and 28. Core component 20 further includes connectors 38 and 40interconnecting core component sections 34 and 36, respectively, to corecomponent section 24.

[0053]FIG. 2b shows core component 20 in a configuration wherein corecomponent sections 22, 24, 26, and 28 (not shown) form the sides of abox while core component sections 34 and 36 form a top and bottom forthe box. A VIP containing single core component 20 can form aninsulating box when the core component is in the configuration of FIG.2b.

[0054]FIG. 3a shows core component section 50 that has opposing faces 60and 62 (not shown), and opposing edges 64 and 66 (not shown) which areeach beveled to bevel angles 69 and 68, respectively. In general,opposing edges can have different bevel angles, although bevel angle 68is preferably the same as bevel angle 69 in core component 50. Forconvenience, identify face 60 as an inside face and face 62 as anoutside face. Outside face 62 has a larger surface area than inside face60.

[0055]FIG. 3b shows core component 80 comprising core component sections51, 52, 53, 54, and 55, each similar to core component section 50 inthat each of such sections have two bevel angles, each of which is 36°.Core component sections 51, 52, 53, 54, and 55 each have opposing beveledges (shown only in FIG. 3b) 90 and 91, 92 and 93, 94 and 95, 96 and97, and 98 and 99, respectively. The core component sections aretouching along lines 82, 83, 84, and 85, thereby creating continuousoutside face 86 along the core component. Connectors 70 and 72 attach toa portion of outside face 86 of core component 80, interconnecting corecomponent sections 51, 52, 53, 54, and 55.

[0056]FIG. 3c shows core component 80 bent such that beveled edges 90and 99 (shown in FIG. 3b) meet. Adjacent beveled edges 91 and 92, 93 and94, 95 and 96, and 97 and 98 (shown only in FIG. 3b) also meet. In theconfiguration of FIG. 3c, core component 80 forms a wall for afive-sided container having a continuous outside face 86 and acontinuous inside face 87 (shown only in FIG. 3c). A VIP containing corecomponent 80 can form the walls of a five-sided insulated container byfolding the core component, and thereby the VIP, into the configurationshown in FIG. 3c. VIP 80 can also be provided with a top, a bottom, orboth in a manner similar to that illustrated in FIGS. 2a and 2 b.

[0057] VIPs having core component sections similar to core componentsection 50 are useful for forming containers having three or more sideswherein edges of adjacent sides contact each other. Preferably, such aVIP has a core component that includes one core component section foreach side of the container and each core component section has bevelangle equal to 180° divided by the number of sections in the corecomponent, or 180° divided by the number of sides to the container.

[0058] Shapeable VIPs of the present invention preferably have a thermalconductivity, according to ASTM method C-518-98, of 0.083 BritishThermal Unit-inch per hour-square foot-degree Fahrenheit(BTU*in/hr*ft²*°F) (12 milliwatt per meter-Kelvin (mW/m*K)) or less,more preferably 0.056 BTU*in/hr*ft²*°F (8.1 mW/m*K) or less, and stillmore preferably 0.042 BTU*in/hr*ft²*°F (6.0 mW/m*K) or less.

[0059] Shapeable VIPs may further comprise additives, such aswater-absorbent materials or getters within the VIP. Water-absorbentmaterials are useful to capture any moisture that is trapped within aVIP. Similarly, getters are useful to capture gases such as oxygen,nitrogen, carbon dioxide, helium and hydrogen that are trapped within aVIP. Both water absorbers and getters help maintain a vacuum within aVIP. Suitable water-absorbent materials include anhydrous calcium oxide,anhydrous barium oxide, anhydrous silica gel, anhydrous silica powder,and anhydrous molecular sieves. Suitable getters include alloys ofbarium, lithium, and cobalt oxide. One commercially available getter isavailable under the trademark COMBGETTER™ from SAES getters. Additivesmay or may not be bound to one or both of a single core component or agas-impermeable barrier of the present invention.

[0060] The present invention also relates to an insulating containercontaining at least one shapeable VIP having a single core component. Ashapeable VIP may form the container itself, or act as an insulatingcomponent within or around a container shell such as a box or a tube. Acontainer comprises a wall structure having opposing top and bottomends. The wall structure encloses a volume, which is the inside thecontainer. The wall structure can be any conceivable shape, for example,cylindrical or rectilinear. A container typically includes a baseattached to the bottom of the container and a lid for covering the topof the container. Preferably, the base and lid also contain a VIP. Morepreferably, a container includes a gasket between its lid and the wallstructure. A gasket may also exist between a base and the wallstructure.

[0061]FIG. 2b shows a core component in the form of a container. A VIPcontaining the core component of FIG. 2a may assume the configuration ofFIG. 2b to create an insulating container of the present invention.

[0062] Similarly, FIG. 3c shows a core component in the form of apentagonal wall structure. A VIP containing the core component of FIG.3b can assume the configuration in FIG. 3c, thereby creating aninsulated wall structure for a container.

[0063] Two or more shapeable VIPs may work cooperatively to form aninsulating container of the present invention. For example, two VIPs inan orthogonal “C” orientation can combine to form a six-sided insulatingcontainer.

[0064] A VIP containing a single core component section may also form awall structure for a container. For example, FIG. 4 shows insulatingcontainer 100 consisting of container shell 102 and VIP 104. VIP 104contains a single core component section (not shown), opposing ends 106and 108, and opposing faces 110 and 112. Ends 106 and 108 meet and VIP104 forms a continuous VIP wall structure. Taping ends 106 and 108together helps maintain the continuous wall structure. Alternatively,end 106 or end 108 may meet face 110 to form a similar VIP wallstructure, not shown. Other shapes of container shells, such ascylindrical or polyhedral, would work equally well as container shell102. VIP 104 may assume a cylindrical shape with a circular crosssection as in FIG. 4, or it may assume a teardrop or oval cross section.

[0065] A protective film or other material may cover one or moresurfaces of the VIPs to enhance durability. A protective film isparticularly useful for protecting VIPs in the absence of any containerother than the VIPs.

[0066] A skilled artisan can conceive of many ways to use a shapeableVIP to form a thermally insulating container.

[0067] The following examples further illustrate but do not limit thescope of the present invention.

Example (Ex) 1. Shapeable VIP Containing a Single Core Component Section

[0068] Prepare a bag from two sheets of polymeric film (such as MYLAR250 RSBL 300 film) that are each 37 inches (in.) (94 centimeter (cm))long and 13.5 in. (34 cm) wide. Overlay one sheet on the other sheet andheat seal three edges together using a heat seal bar at 120-150° C. toform a bag with an open end.

[0069] Cut a single core component from a polymeric foam that is greaterthan 95% open celled (for example, INSTILL™-UC foam, INSTILL is atrademark of The Dow Chemical Company). The single core component is 10in. (25 cm) wide, 35 in. (89 cm) long, and 1 in. (2.5 cm) thick.

[0070] Insert the foam core component into the bag. Place the bagcontaining the foam core component inside of a vacuum chamber andposition a heat seal bar at the open end of the bag. Evacuate thechamber to a pressure of 0.1 torr or less and then clamp the heat sealbar (at 120-150° C.) onto the open end of the bag, thereby sealing thebag and creating a VIP (Ex 1). Relieve the vacuum and remove Ex 1.

[0071] Bend Ex 1 into a teardrop configuration such that opposing endsof Ex 1 contact each other. Tape the ends together using adhesive tape.Insert Ex 1 into a 12 in. (30.5 cm) by 12 in. (30.5 cm) by 12 in. (30.5cm) corrugated box, thereby fabricating an insulated container similarto that in FIG. 4.

[0072] Ex 1 illustrates a shapeable VIP having a single core componentcomprising a single core component section that is free of grooves andthe use of such a VIP in forming an insulating container.

Ex 2. A Shapeable VIP Having an Indirectly Interconnected Core Component

[0073] Create a core component consisting of four indirectlyinterconnected core component sections. Each core component section is apolymeric foam similar to that of Ex 1. Cut four pieces of foam intorectangular core component sections that are 1 in. (2.5 cm) thick andhave opposing 10 in. (25 cm) long edges and opposing 11 in. (28 cm) wideends. Position the four core component sections in a row such that the11 in. (28 cm) wide ends of each core component section are collinearwith the 11 in. (28 cm) wide ends of each other core component section.Adjacent 10 in. (25 cm) long edges are parallel and spaced 1 in. (2.5cm) away from any adjacent core component section edge. Interconnect thecore component sections by adhering two strips of 0.5 in. (1.3 cm) wideadhesive tape (such as SCOTCH brand adhesive tape) across portions ofthe core component sections, similar to the way connectors 30 and 32interconnect core component sections 22, 24, 26, and 28 in FIG. 2a.

[0074] Create a bag with an open end using two 13.5 in. (34 cm) by 47in. (110 cm) sheets of polymeric film, as described for Ex 1.

[0075] Insert the core component into the bag. The adhesive tapeinterconnecting core component sections allows sliding of the corecomponent into the bag as a single unit. The four core componentsections may slide together during insertion into the bag, but pullingon the sections until the tape is taut restores a 1 in. (2.54 cm)spacing between sections. Evacuate the bag and seal it as described forEx 1 to create Ex 2.

[0076] Fold Ex 2 along the connectors to form a four-sided wallstructure with each core component section within Ex 2 corresponding toa side. Prepare an insulating container by inserting the wall structureinto a container shell. Alternatively, apply tape as necessary to securethe wall structure from unfolding and add a lid and base to create aninsulated container. The lid and base may be VIPs.

[0077] Ex 2 illustrates a VIP having an indirectly interconnected singlecore component that is free of grooves and the use of such a VIP to forman insulating container.

What is claimed is:
 1. A vacuum insulation panel comprising a singlecore component enclosed within a gas-impermeable barrier; wherein saidvacuum insulation panel can bend or fold at least 90 degrees relative toan initial configuration without breaking said single core componentinto two or more discrete pieces when said single core component is freeof grooves; and wherein said single core component contains less than 50weight-percent of fiberglass fibers, based on single core componentweight.
 2. The vacuum insulation panel of claim 1, wherein said singlecore component contains at least one core component section comprising apolymeric foam that is 90 percent or more open-celled according toAmerican Society for Testing and Materials method D2856-A.
 3. The vacuuminsulation panel of claim 2, wherein said polymeric foam comprises atleast one polymer selected from the group consisting of polypropylenehomo- and copolymers, polyethylene homo- and copolymers, polystyrenehomo- and copolymers, polyurethane, and polyisocyanurate.
 4. The vacuuminsulation panel of claim 2, wherein the polymeric foam comprisespolystyrene.
 5. The vacuum insulation panel of claim 2, wherein saidgas-impermeable barrier is a multilayer polymeric film that includes aheat sealable layer.
 6. The vacuum insulation panel of claim 1, whereinsaid single core component comprises two or more interconnected corecomponent sections.
 7. The vacuum insulation panel of claim 6, whereinsaid core component sections are interconnected by at least one materialselected from the group consisting of polymeric films and foams,adhesive films, corrugated metal, adhesive tape, paper, metal foil,string, wire, and glue.
 8. The vacuum insulation panel of claim 1,wherein said core component is essentially free of fiberglass, glasswool, and mineral wool.
 9. The vacuum insulation panel of claim 1,wherein said core component contains at least one core component sectionthat has loose particulate material inside of a container.
 10. Thevacuum insulation panel of claim 1, wherein said gas-impermeable barriercomprises a polymeric film.
 11. The vacuum insulation panel of claim 10,wherein said polymeric film is a multilayered polymeric film.
 12. Thevacuum insulation panel of claim 11, wherein said multilayered polymericfilm has an exposed layer that is heat sealable.
 13. The vacuuminsulation panel of claim 11, wherein said multilayered polymeric filmincludes a coating disposed on at least one surface.
 14. The vacuuminsulation panel of claim 13, wherein said coating is selected from thegroup consisting of metal, ceramic, glass, and organic materials. 15.The vacuum insulation panel of claim 1, wherein said vacuum insulationpanel has a D/T ratio of less than
 48. 16. An insulated containercomprising at least one vacuum insulation panel of claim
 1. 17. Theinsulated container of claim 16, further comprising a container shell,wherein said vacuum insulation panel fits around or within saidcontainer shell.
 18. The insulated container of claim 17, wherein saidvacuum insulation panel conforms to said container shell.
 19. A methodof insulating a container shell comprising: (a) bending the vacuuminsulation panel of claim 1 into a desired configuration; then (b)disposing the vacuum insulation panel into or around said containershell.
 20. The method of claim 19, wherein said desired configurationconforms to said container shell.